System and method for lateral transfer plate having a punched tab

ABSTRACT

The present disclosure relates to prefabricated building panels for use in structures, and walls external to structures, such as outdoor privacy walls and the like. More particularly, the present disclosure relates to a method and system for providing building panels that provide improved structural integrity, distribute loads, thermal performance, among other attributes using conventional framing members.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a nonprovisional of, and claims priority to, and thebenefit of U.S. Provisional Application No. 61/918,224, entitled “SYSTEMAND METHOD FOR LATERAL TRANSFER PLATE HAVING A PUNCHED TAB,” filed onDec. 19, 2013, which is hereby incorporated by reference in itsentirety.

FIELD

The present disclosure relates to prefabricated building panels for usein structures, and walls external to structures, such as outdoor privacywalls and the like. More particularly, the present disclosure relates toa method and system for providing prefabricated building panels thatprovide improved structural integrity, distributed loads, and thermalperformance among other attributes.

BACKGROUND

Recent changes in the construction industry have led to an increased useby builders of prefabricated building components manufactured offsite.Despite its many benefits, however, builders have not fully embracedprefabricated building components using alternatives to conventionalwood framing. For example, even though steel framing has many advantagesover conventional wood framing, there has been reluctance in residentialconstruction, and some types of commercial construction, to usecomponents made from steel, rather than wood, due in part to the beliefthat steel is more costly. Dimensioned lumber prices, however, arehighly volatile. An insulated steel frame panel system that is costcompetitive to conventional wood framing, incorporates recognized andreadily available components, and that is easily and quickly assembledand installed, has many advantages over conventional wood framing andwould be embraced by the building industry and building owners.

A number of panels have been designed that incorporate foam insulationfor improved thermal performance These panels, however, oftenincorporate nonstandard light gage steel framing members (e.g., U.S.application Ser. No. 11/825,562 to Miller, U.S. application Ser. No.11/282,351 to Onken et al., U.S. patent application Ser. No. 11/068,609,to Rue, U.S. Patent Application Publication No. 2011/0047912 to Armijo,U.S. application Ser. No. 11/361,189 to Bowman) and often require themanufacture of the panel within a mold, (e.g., Rue and U.S. Pat. No.5,799,462, to McKinney). Others envision the insertion of framingmembers in larger channels or voids in the foam or that require anadhesive to lubricate the stud insertion and/or to adhere the stud inthe foam (e.g., Miller).

New building codes recognize the importance of eliminating thermalbridging. Newer codes require a layer of continuous insulation unless awall assembly can demonstrate an acceptable level of thermal performancewithout it. The layer of continuous insulation creates new buildingchallenges, among which are fastening and exterior finish details,moisture control, and the ratio of rigid continuous insulation to battor other air permeable insulation in the wall cavity.

Since a structural panel by nature generally requires support on boththe exterior and interior of the panel, some panelized systems usenonstandard steel framing members in order to create sufficient strengthin the steel member to avoid multiple connecting bridges through thepanel. For example, the nonstandard framing member in Miller hasadditional bends in the steel framing member to provide additionalstrength. While such efforts can help avoid thermal bridging, the use ofa nonstandard framing member generally requires extensive and expensivetesting to demonstrate compliance with building codes, includingstructural analyses and fire testing under superimposed loads if thefoam is intended to serve any primary structural support purpose. Apanelized system that minimizes thermal bridging but which emphasizesthe use of conventional steel framing members will be more economical tomanufacture and will ensure more rapid acceptance by the buildingindustry.

Other building panel systems that incorporate nonstandard light gagesteel members and foam insulation have addressed thermal bridging invarious ways, but generally are designed in ways that will also requiresubstantial structural (and other) testing to gain acceptance by thebuilding industry and building code officials. Also, they generallyrequire a manufacturing process that is complex and not economical.These factors have generally limited the commercial practicability ofthese approaches.

In traditional construction, cable/utility runs in walls are not wellintegrated with the framing. Groupings of tubing (such as PEX plumbing),electrical, data, voice, and audio wiring are often commingled or loosein a common area within a cable/utility run wall cavity. These cables,wires and tubing are generally secured in wood framing using secondarymeans (such as staples, nails, clips, and tacks), which may puncture thecables, wires and/or tubing upon coupling to the wall. In steel framing,similar attachment means are used such as tie wire, clips, hangars, andmechanical fasteners, each of which may also puncture or abrade thecables, wires, and/or tubing. Moreover, the channel/utility run oftenresults in an opening for thermal, sound, and vibration inefficiencies.In a solid panel system, planning for the placement of cable and utilityrun is an important feature.

SUMMARY

These above disclosed needs are successfully met via the disclosedsystem and method.

In accordance with various aspects, a method and system for providingpanels with improved thermal, acoustic, and vibration characteristics isdisclosed. In accordance with various embodiments of the presentdisclosure a method and system for providing precision cuts to tighttolerances to allow insertion of conventional framing members inexoskeletal panels of variable design length, width, and thickness, in adesired axis (such as the X, Y or Z axis in a Cartesian coordinatesystem) without use of a lubricant or securing adhesive is disclosed,and without the use of cumbersome and limiting EPS panel moldingprocesses. In this way, conventional materials may be used in anon-standard application. Thus, stringent building codes based onconventional shaped and formed materials, such as C shaped studs, may befashioned into a panel using precision cut grooves.

In accordance with various embodiments of the present disclosure, todistribute loads across the exoskeleton, a lateral transfer plate and/orstud tie track is disclosed for use in these exoskeletal panelsintegrated with a foam core, permitting the framing to be staggered andproviding the same or different stud spacing on each side of the panel.Further, a method and system for the lateral transfer plate to be usedas integrated fireblocking in such panels is disclosed.

In accordance with various embodiments of the present disclosure a panelcomprising a polymeric insulated core comprising a steel exoskeleton ofsteel studs, and a lateral transfer plate comprises an opening toreceive a first stud, wherein the opening corresponds to the shape ofthe first stud is disclosed. Further, in accordance with additionalembodiments of the present disclosure, the lateral transfer plate mayinclude an optional flange configured to be fastened to the first stud.The lateral transfer plate may include a punched tab configured to befastened to the first stud. The panel is constructed from parts inaccordance with AISI S200 requirements. Moreover, the lateral transferplate may be configured to be integrated into a furring wall panel inwhich a plurality of studs are arranged in a row. The lateral transferplate may be configured to share the load between the interior andexterior staggered studs, act as mid-height blocking/bracing to reducethe unbraced length of the stud, and/or provide supplemental bracingthat would generally be supplied in part by sheathing.

In accordance with additional embodiments of the present disclosure, apanel comprising a first polymeric insulated core and a contiguousprecision cut groove cut out of the core configured to receive a firststeel stud, wherein the precision cut groove corresponds to the shape ofthe first stud is disclosed. The first steel stud may be a conventionalsteel stud. The conventional steel stud may be a C shaped conventionalsteel stud comprising a web, a flange and a lip. The C shaped stud maybe oriented in any suitable orientation; however, in an embodiment, thestud is oriented such that a long side of the C shaped stud is orientedorthogonal to the face of the panel. This C shaped stud is traditionallyslid into position from the top or bottom edge of the panel.

Such systems, methods, and panels can be used for and by builders ofprefabricated building components, commercial buildings, residentialbuilding, storage or containment structures, exterior soundbarrier/privacy walls, mobile structures, and other types of walls andenclosures. Such systems, methods and panels can suitably distributeloads, improve thermal performance, vibration dampening, structuralintegrity, and provide fire-blocking capability.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present disclosure may be derivedby referring to the detailed description and claims when considered inconnection with the Figures, where like reference numbers refer tosimilar elements throughout the Figures, and:

FIG. 1A is a plan view of the lateral transfer plate according to anexemplary embodiment;

FIG. 1B depicts a side view of a “C” shaped lateral transfer plateaccording to an exemplary embodiment

FIG. 1C depicts a side view of a “Z” shaped lateral transfer plateaccording to an exemplary embodiment;

FIG. 1D is a top cut away view of a template prior to bending to formone or more flanges into either a C shaped lateral transfer plate, a Zshaped lateral transfer plate, or an L shaped lateral transfer plate andprior to punching or cutting the penetrations for the stud profilesaccording to an exemplary embodiment;

FIG. 1E is a wall panel section showing a C shaped lateral transferplate integrated in a panel according to an exemplary embodiment;

FIG. 1F is a wall panel section showing a Z shaped lateral transferplate integrated in a panel according to an exemplary embodiment;

FIG. 1G depicts a side view of an “L” shaped lateral transfer plateaccording to an exemplary embodiment,

FIG. 2A is a plan view of a wall panel assembly according to anexemplary embodiment;

FIG. 2B is a side view of a stud tie track profile according to anexemplary embodiment;

FIG. 2C is a side cut away view of a wall panel with stud tie trackintegrated into the panel comprising a lap joint according to anexemplary embodiment;

FIG. 2D is a side view of a wall panel with an integrated stud tie trackaccording to an exemplary embodiment;

FIG. 3A is a side view of a slip transfer plate according to anexemplary embodiment;

FIG. 3B is an isometric view of the slip transfer plate showing the studprofile penetrations and the slip fastener slots in the flangesaccording to an exemplary embodiment;

FIG. 3C is a side view of a wall panel with a slip transfer plateaccording to an exemplary embodiment;

FIG. 4 is a side cut away view of integrated fireblocking according toan exemplary embodiment;

FIG. 5 is a side cut away view of a fire resistance rated wall panelsystem with integrated fireblocking according to an exemplaryembodiment;

FIGS. 6A-6C depict a top cut away view of a wall panel comprising aformed chase (utility run) and a multipurpose chase (utility run) withstuds oriented in both the X axis orientation and Y axis orientationaccording to an exemplary embodiments;

FIG. 7 is a side cut away view of a wall panel with a split steel track,integrated acoustical sound/fire material, and integrated side air gapaccording to an exemplary embodiment;

FIG. 8 is a top cut away view of a corner assembly of adjoining wallpanels according to an exemplary embodiment;

FIGS. 9A and 9B are segmented side cut away views of a matrix ofinterlocking panels according to an exemplary embodiment.

FIG. 10A depicts a three dimensional view of flangeless lateral transferplate comprising a stud attachment tab according to an exemplaryembodiment;

FIG. 10B depicts a three dimensional view of the flangeless lateraltransfer plate of

FIG. 10A according to an exemplary embodiment;

FIG. 10C depicts a plan view of the flangeless lateral transfer plate ofFIGS. 10A and 10B according to an exemplary embodiment;

FIG. 10D depicts a section view of the flangeless lateral transfer plateof FIGS. 10A through 10C according to an exemplary embodiment;

FIG. 10E depicts a plan view of the flangeless lateral transfer plate ofFIGS. 10A and 10B with attached metal strapping according to anexemplary embodiment;

FIG. 10F depicts a section view of the flangeless lateral transfer plateof FIGS. 10A through 10C with attached metal strapping according to anexemplary embodiment

FIG. 11A depicts a three dimensional view of lateral transfer platecomprising a stud attachment tab according to an exemplary embodiment;

FIG. 11B depicts a three dimensional view of the lateral transfer plateof FIG. 11A according to an exemplary embodiment;

FIG. 12A depicts a three dimensional view of lateral transfer platecomprising a stud attachment tab according to an exemplary embodiment;

FIG. 12B depicts a three dimensional view of the lateral transfer plateof FIG. 12A according to an exemplary embodiment;

FIG. 13A depicts a three dimensional view of lateral transfer platecomprising a stud attachment tab according to an exemplary embodiment;

FIG. 13B depicts a three dimensional view of the lateral transfer plateof FIG. 13A according to an exemplary embodiment;

FIG. 14A depicts a three dimensional view of lateral transfer platecomprising a stud attachment tab according to an exemplary embodiment;

FIG. 14B depicts a three dimensional view of the lateral transfer plateof FIG. 14A according to an exemplary embodiment;

FIG. 15A depicts a three dimensional view of lateral transfer platecomprising a stud attachment tab according to an exemplary embodiment;and

FIG. 15B depicts a three dimensional view of the lateral transfer plateof FIG. 15A according to an exemplary embodiment.

FIG. 16A depicts a three dimensional view of lateral transfer platecomprising a stud attachment tab according to an exemplary embodiment;and

FIG. 16B depicts a three dimensional view of the lateral transfer plateof FIG. 16A according to an exemplary embodiment.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The present systems, apparatus and methods are described herein in termsof various functional components and various processing steps. It shouldbe appreciated that such functional components may be realized by anynumber of hardware or structural components configured to perform thespecified functions. For example, the present disclosure may employvarious foam core portions in varying densities or foam types, andconventional stud framing members and the like whose structure,dimension, gage, and composition may be suitably configured for variousintended purposes. In addition, the present systems, apparatus andmethods described herein may be practiced in any application wherebuilding panels are desired, and the examples herein are merely forexemplary purposes, as the systems, apparatus and methods describedherein can be applied to any similar application.

A simple prefabricated building product that incorporates conventionallight gage steel framing members in a manner that minimizes thermalbridging sufficiently to meet energy efficiency requirements without theneed for a separate layer of continuous insulation provides significantadvantages over prior systems. To gain acceptance, such a system shouldbe cost competitive to manufacture and install. For example, inaccordance with various embodiments, a method and system for providingbuilding panels 150 with an improved steel exoskeleton that makesefficient use of conventional steel components while meeting loadrequirements is described. Such systems, methods and panels 150 can beused for and by builders of prefabricated building components,commercial buildings, residential building, storage structures, exteriorsound barrier walls, mobile structures, and other types of walls andenclosures.

In various embodiments, one or more panels 150 may include a core 151made of an insulating material, preferably, expanded polystyrene (EPS)ranging in density from about 0.75 pcf to about 3.0 pcf. Importantly,the panels 150 may include an exoskeleton of stiffeners (studs 120);each spaced, such as to national and international building coderequirements at 24-inches on center (24″ OC) or 16-inches on center (16″OC), to form a rigid support framework. The studs 120 may be made ofgalvanized steel, in various gages according to structural and buildingcode requirements, such as AISI S200.

The result is a prefabricated panel system that incorporatesconventional light gage steel framing members in an exoskeletal designthat minimizes thermal bridging, but permits the manufacture of panelsto a building's specifications without the requirement of a complex andlimiting panel molding process. A panel system which is economical tomanufacture, and meets energy efficiency requirements without a layer ofcontinuous insulation outside the panel. A panel design that allows theinsertion of conventional steel framing members within foam profiles cutto tight tolerances such that the framing member may be inserted withoutlubricant or adhesive, yet fits snugly within the panel after insertionand the exposed steel is flush with the surfaces of the foam in thepanel is achieved. For instance, using the present system a conventionalstud, which generally comprise a web, a flange and a lip, may beinserted into a precision fit in grooves. Additionally, according tovarious embodiments, a system and panel which distributes loads acrossthe exoskeleton and addresses or eliminate unbraced flanges in orderthat the exoskeletal wall will distribute loads efficiently and meetbuilding requirements without the use of heavier than normal steel gagemembers is achieved.

Historically, EPS panel makers have attempted to use non-conventionalsteel studs (which lack the web, a flange and a lip of a conventionalsteel stud) as they have encountered problems inserting theseconventional steel studs into EPS cut-outs. Other makers have employed acumbersome, inflexible, and expensive molding process.

Unlike in conventional wood or steel framing, the studs 120 do notextend from the exterior surface to the interior surface. Instead, thestuds 120 forming the exoskeleton are each inserted in grooves 170precision cut in the foam core to mirror the shape and form of the stud120. As used herein, to mirror refers to substantially track, correspondto, complement and/or follow, such as by approximating the contoursand/or exterior shape of an element. Accordingly, conduction across thestuds 120 from the exterior to the interior, and vice versa, does notoccur because the studs 120 do not extend through the panels 150,thereby minimizing thermal bridges through the panel 150. In anexemplary embodiment, the panels 150 may have a top track 180 and abottom track 190, which may be attached prior to or during panel 150installation. These tracks (180, 190) may be made from steel, such asconventional steel track. The panel bottom tracks 190 are attachable toa floor, such as a concrete floor, using suitable fasteners. The paneltop tracks 180 are attachable to a ceiling using suitable fasteners. Anysuitable mating or attachment method can be used to join adjacent panels150. Accordingly, workers can build a wall, for example by connecting aseries of panels 150 together, and fastening the bottom 190 and toptracks 180.

In accordance with an exemplary embodiment, an exemplary system 100 andpanel 150 includes an integrated lateral transfer plate 160. Thisintegrated lateral transfer plate 160 can be made of light gage steel,such as 18 gage cold formed steel, or it can be made of other materials,such as carbon fiber that provide lower thermal conductivity combinedwith the material properties required to provide the desired loadtransfers, such as in the lateral direction and, in some applications,fire retardant properties. The stud 120 profiles 168 may be punched orcut into the plate 160 so that the steel studs 120 are inserted throughthe plate 160. The foam core 151 for the panel 150 may be configuredwith pre-cut precision grooves 170 for the studs 120 such that the foamcore 151 may be integrated into the panel 150 assembly that contains thelateral transfer plate 160. In an embodiment, the lateral transfer plate160 contains flanges of any suitable dimension. For instance, theflanges may be between about ¾″ high to 6″ high or greater, depending onthe application (“about” in this context means plus or minus 33% of thedimensional range). The flanges may be fastened to the studs 120 on eachside of the panel 150 exoskeleton with screws or may be welded in someapplications, such as through contact welding. The lateral transferplate 160 with stud 120 profile penetrations can take any suitableshape, such as a “C” shape (See FIG. 1E), much like the shape ofstandard light gage steel track, or it may take a “Z” shape (See FIG.1F) or an “L” shape in certain applications. Referring to the figures,the C shaped lateral transfer plate 160 is illustrated in FIG. 1B. Forinstance, FIG. 1B depicts a side view of a “C” shaped lateral transferplate with a width of “X”, depending on the thickness of the wall panel,and an attachment flange 163 and 166 on opposite sides, with the lengthof “Y” and “Z” variable from about ¾″ to 6″ or more according to anexemplary embodiment, depending on the application. FIG. 1C depicts aside view of a “Z” shaped lateral transfer plate with a width of “X”,depending on the thickness of the wall panel, and an attachment flange163 and 166 on opposite sides, with the length of “Y” and “Z” variablefrom about ¾″ to 6″ or more according to an exemplary embodiment,depending on the application. FIG. 1G depicts a side view of an “L”shaped lateral transfer plate with a width of “X”, depending on thethickness of the wall panel, and an attachment flange 163 and a straightattachment extension 167 on the opposite side, with the length of “Y”and “Z” variable from about ¾″ to 6″ or more according to an exemplaryembodiment, depending on the application. In various embodiments, thelateral transfer plate 160 may be integrated into a furring wall panelin which the studs 120 are arranged in a single row. One flange of theplate 160 may be fastened to the interior of an exterior wall, such as amass wall comprising concrete or CMU, to provide an insulated interiorfurring wall. A portion of the flange in such plate 160 may be cut awayso that the fastening points become separate tabs and not a continuousflange. The lateral transfer plate 160 may be configured to share theload between the interior and exterior staggered studs 120, act asmid-height blocking/bracing to reduce the unbraced length of the stud120, and/or provide supplemental bracing that would generally besupplied in part by sheathing.

In an exemplary embodiment, the integrated lateral transfer plate 160may permit the gage of the steel studs 120 used in the panel'sexoskeleton to be reduced from what would be requisite without thelateral transfer plate 160, but enable the panel 150 to still meet orexceed the required loads. The lateral transfer plate 160 may also allowconsistent stud 120 spacing in the panels, such as at 24″ on center, fora variety of wall panel applications. The lateral transfer plate 160 mayalso have one or both of its flanges made longer to enable the lateraltransfer plate 160 to serve as an exterior or interior ledger in someapplications, such as a ledger to which an exterior deck or otherexterior horizontal building component may be affixed. The lateraltransfer plate 160 may be created in various shapes to match the profileof associated wall components. For example, a lateral transfer plate 160that mirrors the shape and dimensions of an “L” or “Z” shaped cornercomponent 200 in this panel system 100 can simplify the production andinstallation of the plate 160 in a wall corner by eliminating the needfor two separate plates 160 and by avoiding cutting, mitering, andoverlapping of two separate corner plates. In some applications, thelateral transfer plate 160 may have an extension 167 that overlaps thelateral transfer plate 160 in the adjacent wall panel 150 to give thelateral transfer plate 160 continuity in the horizontal plane (See 169in FIG. 1A), or the lateral transfer plate 160 may abut the adjacentlateral transfer plate 160 without overlap.

Historically, panel designs ignored integrated fireblocking. Here, thelateral transfer plate 160 may have a fire retardant layer above orbelow the lateral transfer plate 160 to enable the lateral transferplate 160 with fireblock configuration to be used in a wall wherefireblocking is desired, such as an exterior nonbearing wall in amulti-floor building. In accordance with an exemplary embodiment, one ormore panels 150 comprising a lateral transfer plate 160, and/or alateral transfer plate 160 with fireblocking configuration areapplicable to a multi-story assembly such as for use in balloon framingconstruction or a curtain wall assembly.

Another exemplary embodiment creates a slip transfer plate 165 placed atthe top of an infill wall panel 150 to improve the structural integrityof the exoskeleton. The studs 120 in the exoskeleton are fastened to theslip transfer plate 165 through slotted 310 flanges in the plate 165,which allow for vertical movement of the floorplate 320 above the panel.The top of the studs 120 may protrude through the stud 120 profilepenetrations 168 cut or punched in the slip transfer plate 165. The sliptransfer plate 165 may be created in various shapes to match the profileof associated wall components. For example, a slip transfer plate 165that mirrors the shape and dimensions of an “L” or “Z” shaped cornercomponent in this panel system 100 can simplify the production andinstallation of the plate 165 atop a wall corner by eliminating the needfor two separate plates and by avoiding cutting, mitering, and/oroverlapping of two separate slip transfer plates 165.

In accordance with another exemplary embodiment to maximize thestructural integrity of the steel exoskeleton and eliminate unbracedflanges, a groove 170 is cut at one or both ends of a panel 150 and astud tie track 125 of cold formed light gage steel is inserted into thegroove 170 in such a way that the stud tie track 125 is contiguous tothe inside flange of each steel stud 120 that forms the wall panel 150exoskeleton. The stud tie track 125 is then fastened to each contiguousstud 120 with appropriate fasteners, such as self-tapping screws or insome applications may be welded to the contiguous studs 120, such asthrough contact welding. The stud tie track 125 ensures that the metalstuds 120 will remain affixed to the panels 150 during shipping,handling, and installation. The stud tie track 125 also improves thestructural strength of the panel 150 by bracing the flanges to resisttorsional forces on the studs 120. In some applications, sill anchorbolts will protrude through the bottom plate 190 or track and fit insidethe stud tie track 125. In an exemplary embodiment, tying studs 120 oneach side of the exoskeleton together produces structural and costbenefits, such as permitting the use of lighter gages of steel stud 120members in more standardized gages and spacing.

In an exemplary embodiment, an exemplary system 100 and panel 150includes an integrated lateral transfer plate 160 that may be made fromsteel or, in certain applications, may be made from another materialproviding similar or better structural and/or thermal qualities, such ascarbon fiber, fiberglass, or HDPE. In one embodiment of the lateraltransfer plate 160, a light gage steel template such as that shown inFIG. 1D is created. For example, as shown in FIG. 1D, a top cut awayview of a light gage steel rolled stock template prior to bending thestock along a flange bending line 162 to form one or more flanges intoeither a C shaped lateral transfer plate, a Z shaped lateral transferplate, or an L shaped lateral transfer plate, and prior to punching orcutting the penetrations 168 for the stud profiles is depicted accordingto an exemplary embodiment. Penetrations 168, such as penetrationsmirroring the shape of the stud 120 profiles used in the panel 150 arecut or punched in the template as shown in FIGS. 1B, 1C, and 1G. Flanges161, 163, or 167 on the lateral transfer plate 160 are created from thetemplate by bending or other means, as shown on FIGS. 1B, 1C, and 1G.The lateral transfer plate 160 can be designed with an integratedextension 167 that will overlap (See FIG. 1A, 169) the shear transferplate on the adjacent panel 150, as shown in FIG. 1A. Fire retardantmaterial can be added above or below the lateral transfer plate 160 tocreate a fireblocking configuration that suitably permits the use of thelateral transfer plate 160 in walls in which fireblocking is desiredand/or required, including curtain walls in a multi-floor building. Inaccordance with an exemplary embodiment, one or more wall panelscomprising a lateral transfer plate 160 in a fireblocking configurationare applicable to a multi-panel assembly such as for use in balloonframing or multistory building with curtain walls. In accordance withanother exemplary embodiment, one or more wall panels comprising alateral transfer plate 160 are applicable to a single story ormultistory wall panel assembly without fireblocking added to the lateraltransfer plate 160 in applications in which fireblocking is not desired.

A fire retardant such as one or more spray, coating, caulking, foiltape, elastomeric, gypsum board, mineral wool, or other material may beintroduced above or below the lateral transfer plate 160. In anembodiment, a fire retardant material is placed on the lateral transferplate 160 before the stud 120 profile penetrations 168 are cut orpunched. In some embodiments, any gaps around the stud 120 penetrations168 are sealed with fire retardant material, which may be the same ordifferent fire retardant material used on the horizontal surface of thelateral transfer plate 160.

Turning to FIG. 1E, a wall section of a panel 150 with an integratedlateral transfer plate 160 shows that the flanges on the lateraltransfer plate 160 are secured to the studs 120, which may be via afastener, contact or other welding, clipping or snapping mechanism,adhesive tape, or other means of securing the lateral transfer plate 160to the studs 120. Stated another way, FIG. 1E depicts a wall panelsection showing a C shaped lateral transfer plate 101 integrated in thepanel with the light gage steel exoskeleton of studs and track accordingto an exemplary embodiment. In accordance with an embodiment, and withreference to FIG. 1A, a plan view of the lateral transfer plate 160 withexamples of the stud profile penetrations 168 to be cut or punched isdepicted. Also, an example of an optional extension of the lateraltransfer plate to overlap 169 the lateral transfer plate on an adjacentpanel according to an exemplary embodiment; a part of the lateraltransfer plate 160 may overlap the lateral transfer plate 160 on theadjacent wall panel 150. Such overlap may be unsecured, or may besecured by a fastener, contact or other form of welding, or anappropriate adhesive or sealant.

According to various embodiments, as shown in FIG. 1F, a wall panelsection showing a Z shaped lateral transfer plate 102 integrated in thepanel with the light gage steel exoskeleton of studs and track, in whichembodiment one flange may be longer to serve as a ledger (not depicted).

According to various embodiments, with reference to FIGS. 2A-2D thepresently disclosed system and wall panel assembly may comprise a studtie track. For instance, FIG. 2A depicts a plan view wall panel assemblywith an exploded view of a portion of the panel that contains a lightgage metal stud tie track secured to the studs with fasteners. FIG. 2Bdepicts a side view of a stud tie track profile. FIG. 2C depicts a sidecut away view of a wall panel with stud tie track integrated into thepanel, which panel has an illustrative lap joint. FIG. 2D depicts a sideview of a wall panel with an integrated stud tie track and without anybottom track.

In accordance with another exemplary embodiment, the top track 180 onpanels 150 comprising an infill wall may be replaced by a fire-resistiveslip transfer plate 165 such as that depicted in FIG. 3A and FIG. 3B.For instance, FIG. 3A depicts a side view of a slip transfer plate withlight gage metal studs protruding through the plate according to anexemplary embodiment. FIG. 3A further depicts dimensions A, B, C, and D.Dimension A represents the exterior slip flange dimension. Dimension Brepresents the interior slip flange dimension. Dimension C representsthe slab attachment flange dimension. Dimension D represents the widthof wall panel dimension. Furthermore, FIG. 3A illustrates a light gagemetal stud protruding through metal stud profile penetration 168 and thetop of EPS foam insulation 151. Dimensions A, B, C, D are furtherdepicted in FIG. 3B. FIG. 3B depicts an isometric view of the sliptransfer plate showing the stud profile penetrations and the slipfastener slots in the flanges according to an exemplary embodiment.

The slip transfer plate 165 improves the structural integrity of thepanel 150 by tying the inner and outer steel studs 120 of theexoskeleton together. The slip transfer plate 165 attaches to the studsthrough slotted metal flanges in the plate 165, which flanges allow forvertical movement of the floorplate above the panel 150 that may becaused by thermal, seismic, wind loading, or any other load.

In accordance with another exemplary embodiment, the foam panel coreabove the lateral transfer plate 160 has precision grooves 170 pre-cutto hold and receive the studs 120 comprising the exoskeleton, and thefoam panel 150 core above the lateral transfer plate 160 is integratedwith the studs 120 that extend above the lateral transfer plate 160 in amanner that the studs 120 are securely fit in the pre-cut grooves 170such that the lateral transfer plate 160 becomes integrated within thefoam core of the wall panel 150.

Studs 120 may be inserted from the top and/or bottom of the panel 150retained in the precision cut groove 170, cut to substantially mirrorthe exterior and interior of the stud 120. In this fashion, multiplepanels 150 or core material may be coupled to a single stud 120. Forinstance, a thirty foot long stud 120 may be used to couple three 10foot wide sections of core material (panels 150) together. In the panel150 embodiment that incorporates one or more lateral transfer plates160, the foam core above the lateral transfer plate 160 has precisioncut grooves 170 to match the stud 120 profiles and such foam core isintegrated with the portion of the panel 150 containing the lateraltransfer plate 160 in a manner that the protruding studs 120 integrateinto such grooves 170. This procedure may be repeated on the same panel150 to create a panel 150 of any length with more than one lateraltransfer plate 160.

The stud tie track 125 is formed from cold formed steel such that eachflange of the stud tie track 125 will be contiguous to the inside web ofeach stud 120 forming the wall panel's 150 steel exoskeleton, asdepicted in FIGS. 2B and FIG. 2D. In one example embodiment, this steelis 20 gage. In one example embodiment, stud tie rack 125 has a channelapproximately 1 inch deep. The stud tie track 125 is placed in a pre-cutprecision groove 170 in an end of the wall panel 150 and fastened to thestuds 120 with suitable fasteners, such as self-tapping screws or othermeans of fastening such as welding with contact welding. The stud tietrack 125 holds the studs 120 securely in the wall panel 150 to preventmovement of the studs 120 during assembly, shipping, and installation ofthe wall panel 150. Upon installation of a wall panel 150, the stud tietrack 125 braces the interior flanges and increases the ability of thesteel studs 120 to resist torsional forces, thereby improving thestructural integrity of the wall panel 150. In one embodiment, thefasteners or anchor bolts that fasten the steel bottom plate to thefoundation fit within the stud tie track 125.

In accordance with one aspect of the present invention, an exemplarysystem and panel includes an integrated fireblocking configuration thatsuitably permits the use of an exemplary panel 150 method and system inwalls in which fireblocking is desired and/or required, including in amulti-floor building. For instance, with reference to FIG. 4, a side cutaway view of integrated fireblocking according to an exemplaryembodiment is depicted.

In accordance with an exemplary embodiment, one or more panels 150comprising a fireblocking configuration are applicable to a multi-panel150 assembly such as for use in balloon framing construction. Inaccordance with another exemplary embodiment, one or more panels 150comprising a fireblocking configuration are applicable to potential orreal gaps in fire protection formed along or through the panel 150 (inany axis, such as vertical or horizontal). For instance, thefireblocking configuration may be applied in the case of a soffit orbeam enclosure.

For example, with reference to FIG. 4, a side view of a wall system withintegrated fireblocking construction is depicted. At or in the nearproximity of the location where fireblocking is desired, a first panel150 portion is configured for joining to a second panel 150 portion. Thefirst panel 150 and second panel 150 portions may comprise a completepanel 150 size or they may comprise less than a complete panel 150 size.In some embodiments, the location where fireblocking is desired iswithin about 1.5 inches (plus or minus 0.75″) of the bottom of theintersection of a floor to a wall panel 150 (e.g. bottom track 190),with the panel 150 oriented in a plane 90 degrees from the axis of thepanel 150 construction (as shown).

This configuration for joining may comprise altering the surfaceproperties of the first panel 150 to mate with a receiving second panel150 by any suitable configuration, such as by establishing a joint andreceiving well (as shown). Alternatively, tongue and groove, rounded,jagged, flat and combinations thereof are contemplated for this jointconfiguration. Alternatively, fireblocking could be supported by the useof plates, foils, and angles, as appropriate.

A fire retardant such as one or more spray 450, coating, caulking, foiltape, elastomeric, or other material may be introduced into the jointand/or applied to one or more joint members. In some embodiments, thisspray may be 3M Firedam spray applied to both mating surfaces duringmanufacture, or field applied, as appropriate. This fire retardant maybe applied over the entire joint and/or receiving well surface(s). Insome embodiments, a first fire retardant is applied to the first panel150 edge (e.g. joint) and a second fire retardant is applied to thesecond panel 150 edge, (e.g. receiving well). In an embodiment, thefirst and second panel 150 portions are placed in position and the fireretardant is sprayed into a gap between the joint members (first andsecond panel 150 portions). The gap between joint members may be anysuitable distance. In some embodiments, this gap is between about 0.25inches and about 1.25 inches. In another embodiment, this gap betweenthe joint and the receiving well is about 0.5 inches.

In another embodiment, insulation is positioned between the joint andreceiving well, such as mineral wool batt insulation 410 sandwiched andencapsulated between two metal foil sheets in a continuous roll seam ina manner that the configuration of the joint creates a structuralcomponent. Alternatively, a formed steel plate may be fastened to thestuds to support the integrated fireblocking. This insulation mayimprove the acoustic (sound transmission class) and/or fire safety ofthe wall panel system.

In various embodiments, a second fire retardant, such as an aluminumfoil tape 420, is applied over the fireblocking joint on the panel face.The second fire retardant may be suitably applied to continuously coverthe fireblocking joint on the interior and exterior face of the panel150. An exterior layer of sound, vapor, and/or noncombustible cladding440, such as a drywall, plasterboard, cement board, gypsum board and/orthe like may be applied to either side of the panel 150, such as bysecuring to one or more studs 120. An exterior cladding over flashing430 may be secured to the exterior layer. In some embodiments,additional layers of vapor, sound and/or fire resistant materials may becoupled between the exterior layer and the exterior cladding overflashing 430.

Turning to FIG. 5, a segmented side cut away view of a fire resistancerated wall panel system is depicted. As shown in the top of FIG. 5, onesurface of a track is secured to a ceiling via a fastener, such as asteel slip channel 510 or steel clip secured by a power driven fastener520. A joint surface of a panel 150 (e.g. top edge of the panel) isconfigured to be secured into the track. Between the track and the topjoint surface of the panel 150 a fire retardant, such as one or morespray, coating, caulking, foil tape, elastomeric, or other material maybe introduced into the joint and/or applied to the top joint surfaceand/or the track. This fire retardant may be applied over the entirejoint surface. In some embodiments, a first fire retardant is applied tothe top joint surface and a second fire retardant is applied to thetrack. In an embodiment, the panels 150 are placed in position and thefire retardant is sprayed into a gap between the joint members (trackand top edge surface). As shown in FIG. 5, a fire stop spray and/or fireretardant may coat the intersection of the top exterior and interiorface of the panel 150 and the track and surrounding surfaces. This firestop spray and/or fire retardant may expand (and/or in some casesharden) when exposed to high temperature creating an additionalstructural element and/or enhancing protection from smoke and fire. Invarious embodiments, a structural element and/or fire retardant may becoupled to the fireblocking configuration disclosed herein and/orsurrounding surfaces to further retain the passive fire protectionsystem elements from weakening due to fire, heat, or from instantcooling, impact, and erosion effects of active fire protection, such asfrom water delivered via fire hose, sprinklers or fire extinguishers. Insome embodiments, this coating of fire stop spray and/or fire retardantis applied such that there is at least a 2″ overlap (FIG. 5; DimensionF) at the joint, though overlap can vary. According various embodiments,insulation may be applied to the joint surface, such as mineral woolbatt insulation. According various embodiments, the sheathing isreplaced by two light gage metal skin panels adhered together, with theinner metal panel coated with an intumescent paint or similar fireresistant coating in order to create a fire resistant wall assemblywithout the use of gypsum board.

As shown in the bottom of FIG. 5, one surface of a track may be securedto a floor via a fastener, such as a steel slip channel or steel clipsecured by a power driven fastener 520 (e.g. at bottom track 190). Ajoint surface of a panel is configured to be secured into the track.Between the track and the bottom joint surface of the panel a fireretardant, such as one or more spray, coating, caulking, foil tape,elastomeric, or other material may be introduced into the joint and/orapplied to the bottom joint surface and/or the track. This fireretardant may be applied over the entire joint surface. In someembodiments, a first fire retardant is applied to the bottom jointsurface and a second fire retardant is applied to the track. In anembodiment, the panels are placed in position and the fire retardant issprayed into a gap between the joint members (track and bottom edgesurface). As shown in FIG. 5, a fire stop spray and/or fire retardantmay coat the intersection of the bottom exterior and interior face ofthe panel 150 and the track and surrounding surfaces. In someembodiments, this coating of fire stop spray and/or fire retardant isapplied such that there is at least a two inch overlap at the joint. Inanother embodiment, insulation is applied to the joint surface, such asmineral wool batt insulation. A horizontal multipurpose chase withinterlocking expanded plug 215 (described in greater detail below) isalso depicted in FIG. 5.

Cable and/or utility runs have been addressed in a rudimentary fashionby makers of building panels. In accordance with another aspect of thepresent invention, an exemplary system 100 and panel 150 is configuredto provide a utility run (chase/channel 210) with precision cut grooves170 for retaining cables, wires and tubing. In accordance with anexemplary embodiment, an exemplary panel 150 includes a multi-purposeEPS chase 210 with interlocking EPS plug 215 configured to providecompression channels 210 in the panel 150. The channels 210 are suitablysized to hold low voltage electrical wires, PEX plumbing, and the like.The interlocking EPS plug 215 may be sized to fit in the chase 210. Thisplug may increase the thermal efficiency by avoiding a larger thermalshort.

In accordance with an embodiment and with reference to FIG. 6B, aprecision cut chase 210 is depicted. This chase 210 may be formed usinga computer numerical control (CNC) machine (described in greater detailbelow). This chase 210 may be formed in any desired axis of the panel.As shown, in various embodiments, the depth of the utility run 210 canbe greater than the depth of the studs 120 in the panel so as to preventthe studs 120 from impeding utility runs 210. Additionally, the chase210 can be at a depth to facilitate the use of the knockouts in thestuds 120. In various embodiments, the interior surface of the chase 210is precision cut to comprise one or more channels 212 for securelyreceiving at least one of a tube (such as PEX plumbing), electrical,data, voice, and/or audio wiring. Stated another way, these channels 212are integral to the core formed by removing core material. Each channel212 within the chase 210 may be cut at a pre-selected size tosubstantially mirror the portion of the exterior of a tube, electrical,data, voice, and/or audio wiring desired to be retained by each channel212. These tubes, wires and/or cables may be press fit into place withineach channel 212. Additionally, the disclosed utility chase 210configuration with an EPS rib separating each component providesshielding between data and electrical wires in the same chase 210, whichmay reduce or eliminate the need for mechanical devices to achieve thisshielding. Also, eliminating the entanglement of electrical wiringreduces secondary electromagnetic fields caused by crisscrossed wires.

Each channel 212 may be suitably spaced within the chase 210 such thatthere is a gap between each tube, wire or cable. Each channel 212 may bemarked to assist with installation and coordination of the tubes, wiresand/or cables installed therein. Though FIG. 6B depicts 5 individualchannels 212 (all of a similar size) within the chase 210 it should beappreciated that any suitable number of channels 212 formed in anysuitable respective size may be formed in the chase 210.

In according with various embodiments, an interlocking EPS plug 215 maybe inserted into the chase 210. This configuration may providecompression channels 212 in the panel 150. The interlocking EPS plug 215fits back in the chase 210 and increases the thermal efficiency byavoiding a larger thermal short. In some embodiments, the plug 215 isformed from a portion of the material removed while cutting the chase210 from the core material. This method may both minimize waste materialand ensure a tight fit in the chase 210. The plug 215 is shown with aflat or substantially rectangular cross sectional shape, however itshould be appreciated that the plug 215 may be cut with surface featuresto substantially mirror the portion of the exterior of a tube,electrical, data, voice, and/or audio wiring desired to be retained byeach channel 212. The EPS plug 215 may be cut with tabs extending fromthe side surface such that the extending tabs provide for a securablesemi-permanent or permanent pressure fit in the chase 210. Moreover, thechase 210 may be cut with ridged sidewalls to retain a plug 215comprising extending tabs (as shown).

The chase 210 with precision cut channels 212 may be substantiallyrectangular (as shown) or may be curved (not depicted). Also depicted,in FIGS. 6B-6D a multipurpose chase 210 without precision cut channels212 may be formed in the panel in any desired axis of the panel 150. Inaccordance with an embodiment, this multipurpose chase 210 may beprecision cut to any desired shape or diameter in the core. This chase210 may be formed in any desired axis of the panel 150. This chase 210may be a straight run or may be oriented in any desired direction, suchas having a bend and run from horizontal to vertical. As shown, invarious embodiments, the depth of the utility run (e.g. chase 210) isgreater than the depth of the studs 120 in the panel 150 so as toprevent the studs 120 from impeding utility runs.

Also, with reference to FIGS. 6A-6C, precision cut stud grooves 170,such as hot wire cuts, are depicted. In various embodiments, a hot wirecut may be made in a panel to substantially mirror the exterior surfaceof a stud 120, such as a “C” shaped stud 120 in either or both of the Xaxis (See 610) or Y axis (See 620) orientations. This hot wire cut maybe made by any suitable hot wire cutting tool; however, in an embodimentthat achieves the desired precision the hot wire cutting tool is a CNCfoam cutting machine with which the operator employs optimalcombinations of cutting parameters and methods to achieve tighttolerances around the stud 120 profile. For example, FIG. 6A illustratesa top cut away view of an exemplary wall panel comprising a formed chase(utility run) and a multipurpose chase (utility run) with studs orientedin both the X axis orientation 610 and Y axis orientation 620. FIG. 6Cdepicts a top cut away view of an exemplary wall panel comprising aformed chase (utility run) and a multipurpose chase (utility run) withstuds oriented in the X axis orientation 610. FIG. 6B depicts a top cutaway view of an exemplary wall panel comprising a formed chase (utilityrun) and a multipurpose chase (utility run) with studs oriented in the Yaxis orientation 620.

The CNC foam cutting machine may allow for end-to-end panel design. Thisend-to-end design is highly automated using computer-aided design (CAD)and computer-aided manufacturing (CAM) programs. The programs produce acomputer file that is interpreted to extract the commands needed tooperate a particular machine via a postprocessor, and then loaded intothe CNC machines for production. The complex series of steps needed toproduce any panel is highly automated and produces a part that closelymatches the original CAD design. For instance, in one embodiment,automated measurements of a room layout via a room measuring device,such as a laser, may be made and transmitted and/or input, directly orindirectly through intervening processing, to the CNC machine forproduction. Alternatively, a program for automatically producing panel150 configurations from a CAD design may be automatically translatedinto the machine code to cut the panels on a CNC machine.

Principles of the present disclosure may suitably be combined withprinciples for a panel system and method of manufacture as disclosed inU.S. patent application Ser. No. 12/715,288 filed on Mar. 1, 2010 andentitled, “CONSTRUCTION SYSTEM USING INTERLOCKING PANELS.”

A C shaped conventional stud 120 is depicted, in part, because it ismore commonly used in the industry; however any shape of stud that meetsload requirements may be envisioned (in that regard, C-shapedconventional studs may even appear to pose more difficulty to precisionfit in grooves due to the small “lip” configuration, but can be readilyutilized in accordance with methods and systems disclosed). The studs120 may be formed, such as with a bending or cold steel forming machine,to proprietary specifications and a precision cut 170 may be made in thepanel 150 to substantially mirror these proprietaryspecifications/tolerances. Moreover, this stud 120 forming machine mayby itself, or in combination with another machine, mechanically insertthe formed studs 120 into the precision cut grooves.

In an embodiment, a large block of EPS material may cut into multiplepanels 150 by using a specialized hot wire cutting device preprogrammedwith specific instructions where cuts should be made. The travel path ofthe hot wire may be fine-tuned such that minimal waste is created andavoiding a larger thermal short. The hot wire cutting machine may havemore than one cutting element to cut multiple panels substantiallysimultaneously and/or to make multiple cuts in a single panelsubstantially simultaneously. The hot wire cutting device maytravel/make cuts along any desired axis and/or direction. Also the panel150 being cut may move in any desired axis/direction while being cut.

As discussed herein, studs 120 may be inserted from the top and/orbottom of the panel 150 retained in the precision cut groove 170, cut tosubstantially mirror the exterior and/or interior of the stud 120. Inthis fashion multiple panels 150 or core material may be coupled to asingle stud 120. For instance a thirty foot long stud 120 may be used tocouple three 10 foot wide sections of core material (panels) together.Similarly, a matrix of sections of core material may be coupled togetherusing channels/grooves 170 and studs 120 in multiple axis. For instance,to create a wall, floor, ceiling, or roof (see FIG. 9A and FIG. 9B)panels 150 with an EPS core can be created in any length or width up tothe length or width of the appropriate stud 120, and multiple panels 150may be interlocked using various interlocking edge configurationsprecision cut in the foam core. Each of FIG. 9A and FIG. 9B depicts amatrix of interlocking panels 150 according to various embodiments.

As will be appreciated by one of ordinary skill in the art, the systemfor creating panels 150 and forming precision cuts 170 in panels basedupon plans existing only as prints or existing as electronic CADdrawings may be embodied as a method, device for making the cuts, and/ora computer program product. Additionally, a scanning device may scan theprofile of a steel stud 120 or steel track or other building componentand convert the scanned image to the machine code used by the CNCmachine to cut the corresponding groove 170 or other profile in the EPS.Accordingly, the aspects of the present disclosure may take the form ofan entirely non-transitory software embodiment, an entirely hardwareembodiment, or an embodiment combining aspects of both software andhardware. Furthermore, the present invention may take the form of acomputer program product on a non-transitory computer-readable storagemedium having computer-readable program code means embodied in thestorage medium. Any suitable computer-readable storage medium may beutilized, including hard disks, CD-ROM, optical storage devices,magnetic storage devices, flash card memory and/or the like.

Historically, building panels exhibited poor thermal, vibration, andacoustic characteristics. In accordance with another aspect of thepresent disclosure, and with reference to FIG. 7, an exemplary systemand panel 150 is configured for various other acoustical and thermalimprovements. For instance, FIG. 7 is a side cut away view of anexemplary wall panel with a split steel track 710, integrated acousticalsound/fire material, and integrated side air gap 720 for improvedthermal, fire, and acoustical properties. In accordance with anexemplary embodiment, a system 100 or panel 150 can comprise a splitsteel track 710 with integral gasket 730, such as a foam gasket,configured to create integral sound, vibration, and thermal break at thetrack. This track may be attachable to a ceiling or a floor. In variousembodiments, the track 710 is secured via a power driven fastener 520through the gasket. A steel runner 530, steel clip, steel angle 740 orother steel connector, in the case of a floor or ceiling respectively,may be screwed 540 to the track at one or more studs 120. A continuousbead of sealant 750 (such as acoustical/thennal/joint sealant) may beapplied to the joint surface of the panel and the complementary steeltrack. This sealant may be applied to any joint in the system, such asthe joint of the face of the panel and the chase plug. An air gap 720between a vapor, sound and/or fire barrier and the panel creates ahigher sound and vibration rating.

In accordance with another embodiment, and with reference to FIG. 8, acorner system 200 is depicted. FIG. 8 depicts a top cut away view of acorner assembly of adjoining wall panels. In this system, aninterlocking outside corner steel structural element (stud or othersteel support), and an inside corner steel structural element (stud orother steel support) is depicted, as shown, these structural elementsmay be conventional studs. One or more sections of core material may beprecision cut to receive the outside corner and inside corner structuralelements.

The integral corner depicted in FIG. 8 may eliminate the thermalbridging associated with conventional construction. The corner system200, comprising an integral corner, also allows for the continuity ofhorizontal utility chases that are difficult or impossible to facilitatein conventional construction. The corner system 200, comprising anintegral corner also creates a uni-directional shear connection notcreated in conventional corner construction methods. This corner system200, comprising an integral corner, may also eliminate voids and leaksand to combat a building thermal envelope being compromised as it is inconventional construction methods.

FIG. 8 also depicts a precision cut integral interlocking EPS joint 810.This joint and receiving well does not require secondary fasteners tocouple a first panel 150 and a second panel 150 together. In variousembodiments, an edge of a first panel 150 is fashioned with a precisioncut 170 joint configuration and a second panel 150 is fashioned with aprecision cut receiving well sized to substantially mirror the outersurface of the joint such that the two panels 150 may be pressure fittogether. Though not necessary, retaining elements may be fashioned onthe receiving well and/or the joint surface to securely hold the twopanels 150 together.

According to various embodiments, FIGS. 10A-10D depict a lateraltransfer plate 960. The lateral transfer plate 960 may be fashioned withpunched stud attachment tab 970 corresponding with stud 930 profilepenetrations 920. The tabs 970 may be integrally formed and punchedand/or cut from a flat surface of the lateral transfer plate 960substantially perpendicular to the orientation of length of stud 930.For instance, the tabs 970 may be formed by cutting two (or three in thecase of a lateral transfer plate 960 having a flange) sides of arectangle from the lateral transfer plate 960. The tab 970 may then bebent approximately 90 degrees along the remaining edge of the rectangle.Tab 970 may be formed from a recess configured to accept a stud 930and/or from any flat surface of the lateral transfer plate 960.

The stud attachment tabs 970 may mirror and/or be substantially the samedimensions as the profile penetrations 920. According to variousembodiments the stud attachment tabs 970 may be smaller than the profilepenetrations 920. The stud attachment tabs 970 may be cut into anydesired shape, but as shown in FIGS. 10A-15B, are generally rectangular.As variously depicted by the figures, the stud attachment tabs 970 maybe fastened to the web of the stud (with renewed reference to FIGS.10A-10B), the flange of the stud (with brief reference to FIGS.12A-12B)., or tabs can be punched/cut so that there is a tab for each ofthe web and the flange of the stud 930 (with brief reference to FIGS.16A-16B).

The height of the stud attachment tab 970 may be approximatelyequivalent to the width of profile penetrations 920 and/or the width ofstud 930. The width of the stud attachment tab 970 is approximatelyequivalent to the depth of profile penetrations 920 and/or the width ofstud 930. As depicted in FIGS. 10A-10D, tab 970 may be fastened to thestud 930 as desired. The tabs 970 may be fastened to the studs 930 withscrews, rivets, contact welding, or with adhesive tape, such as 3M VHBtape.

A thermal isolator may be positioned between the tab 970 and the stud930. The thermal isolator may be configured to lessen the thermaltransfer from the lateral transfer plate 960 to the studs 930. Thethermal isolator may be any desired dimension. For instance, the thermalisolator may be less than or equal to about 1/8″ thick. The thermalisolator between the tab 970 and the stud 930 is configured to provide abreak in the metal to metal thermal path. From a thermal perspective,the lateral transfer plate 960 is configured to lessen thermal transferfrom one side to the other. For instance, lateral transfer plate 960introduces discontinuities configured to interrupt what was formerly acontinuous metal path through the wall in conventional framing systems.Stated another way, the design of lateral transfer plate 960 isconfigured to impede efficient thermal transport through lateraltransfer plate 960.

Strapping, such as continuous metal strapping 940, may be applied in thefield, as desired. For instance, and with reference to FIGS. 10E and 1OFa lateral transfer plate 960 may be coupled to an adjacent lateraltransfer plate 960 with a short length of metal strapping that overlapsthe flange of each lateral transfer plate 960 and is screwed into eachadjacent flange. The metal strapping that may be field applied mayextend the entire length of the wall until an opening is reached,corner, or the end of the wall for a flangeless lateral transfer plate960 (as depicted in FIG. 10F). With the flangeless lateral transferplate 960, the practice of tying a first lateral transfer plate 960 toan adjacent lateral transfer plate 960 may be obviated.

According to various embodiments, FIGS. 11A-11B depict a lateraltransfer plate 960 comprising a flange 1065. Stud attachment tab 1070may be punched forming an aperture 1020 bounded on three side by thelateral transfer plate 960 and on one side by flange 1065. As previouslydescribed, flange 1065 may be coupled to the stud 930 and/or tab 1070may be coupled to the stud 930.

According to various embodiments, FIGS. 12A-12B depict a lateraltransfer plate 960 comprising a stud attachment tab 1170. Attachment tab1170 may be configured to be attached to the web 935 of the stud 930.The tabs 1170 may be cut such that the resultant tab 1170 extends pastthe stud 930 to (or past) the centerline of the lateral transfer plate960. In this way, the loads on the studs 930 and lateral transfer plate960 may be transferred appropriately. As used herein, the centerlineruns in the X direction and generally bisects the lateral transfer plate960 in Y direction. Attachment tab 1170 may be any desired height. Forinstance, attachment tab 1170 may be equivalent to the depth of the cutout 1120 and or the width of stud 930. According to various embodiments,the height of attachment tab 1170 may be less than the depth of the cutout 1120 and or the width of stud 930.

According to various embodiments, FIGS. 13A-13B depict a lateraltransfer plate 960 comprising a plurality of stud attachment tabs 1270and 1275 configured to be attached to each stud 930. As previouslymentioned, studs 930 may be oriented in both the X axis orientation andY axis orientation. For instance, as compared with FIGS. 12A and 12B theorientation of studs 930 of FIGS. 13A-13B are rotated 90 degrees.Attachment tabs 1270 and 1275 may be configured to be attached to twosides (such as the flanges) of each stud 930. Attachment tab 1170 may beany desired height. For instance, the height of attachment tab 1270 and1275 may be equivalent to the one half the width of recess 1120 and orthe width of stud 930. According to various embodiments, the height ofattachment tab 1270 and 1275 may be less one half the width of recess1120 and or the width of stud 930.

According to various embodiments, FIGS. 14A-14B depict a lateraltransfer plate 960 comprising a flange 1065. Stud attachment tab 1370may be punched forming an aperture 1325 bounded on three side by thelateral transfer plate 960 and on one side by flange 1370. Studattachment tab 1370 may be punched forming a recess 1320 bounded onthree side by lateral transfer plate 960.

According to various embodiments, FIGS. 15A-15B depict a lateraltransfer plate 960 comprising a stud attachment tab 1470. Studattachment tab 1470 may be formed as part punch/cutting two sides oflateral transfer plate 960 to form recess 1420. According to variousembodiments, FIGS. 16A-16B depict a lateral transfer plate 960comprising a stud attachment tab 1570 and 1575. Attachment tabs 1570 and1575 may be oriented along different planes and configured to be coupledto two surfaces of stud 930, such as both the web and the flange of stud930. In this way, multiple attachment tabs 1570 and 1575 may be formedfrom a single punched recess 1520.

According to various embodiments, a wall is the foam is recessed about2.5″ on an interior side to provide a space for electrical distributionwithout having to make any cuts in the foam. For instance, anapproximately 8″ wall, with about 5½″ of foam and about 2½″ of space forservice distribution may be created. In this wall, the lateral transferplate 960 may be any desired width, but may desirably be about 8″ wide.In this way, lateral transfer plate 960 may extend over and cover theservice distribution space. The lateral transfer plate 960 may beconfigured for draftstopping and/or fireblocking applications.Components may be coupled to each lateral transfer plate 960, in certainapplications, to improve its fire resistance/draft resistance. Thelateral transfer plate 960 may be configured to provide a verticalbarrier in the wall. Lateral transfer plate 960 may comprisepenetrations for vertical runs of conduit, as desired.

The present disclosure sets forth exemplary methods and systems forproviding building panels with improved structural, thermal, acoustic,and fire-blocking characteristics. It will be understood that theforegoing description is of exemplary embodiments of the disclosure, andthat the systems and methods described herein are not limited to thespecific forms shown. Various modifications may be made in the designand arrangement of the elements set forth herein without departing fromthe scope of the disclosure. For example, the various components anddevices can be connected together in various manners in addition tothose illustrated in the exemplary embodiments, and the various stepscan be conducted in different orders. These and other changes ormodifications are intended to be included within the scope of thepresent disclosure. Accordingly, the specification is to be regarded inan illustrative rather than a restrictive sense, and all suchmodifications are intended to be included within the scope of thepresent disclosure. Likewise, benefits, other advantages, and solutionsto problems have been described above with regard to variousembodiments. However, benefits, advantages, solutions to problems, andany element(s) that may cause any benefit, advantage, or solution tooccur or become more pronounced are not to be construed as a critical,required, or essential feature or element of any or all the statements.As used herein, the terms “comprises,” “comprising,” or any othervariation thereof, are intended to cover a non-exclusive inclusion, suchthat a process, method, article, or apparatus that comprises a list ofelements does not include only those elements but may include otherelements not expressly listed or inherent to such process, method,article, or apparatus. Also, as used herein, the terms “coupled,”“coupling,” or any other variation thereof, are intended to cover aphysical connection, an electrical connection, a magnetic connection, anoptical connection, a communicative connection, a functional connection,and/or any other connection. Still further, as used herein, the term“about” shall mean within +/−25% of a number, unless stated otherwise.When language similar to “at least one of A, B, or C” is used in thestatements, the phrase is intended to mean any of the following: (1) atleast one of A; (2) at least one of B; (3) at least one of C; (4) atleast one of A and at least one of B; (5) at least one of B and at leastone of C; (6) at least one of A and at least one of C; or (7) at leastone of A, at least one of B, and at least one of C.

In the description herein, references to “various embodiments”, “variousaspects”, “an aspect”, “one embodiment”, “an embodiment”, “an exampleembodiment”, etc., indicate that the embodiment described may include aparticular feature, structure, or characteristic, but every embodimentmay not necessarily include the particular feature, structure, orcharacteristic. Moreover, such phrases are not necessarily referring tothe same embodiment. Further, when a particular feature, structure, orcharacteristic is described in connection with an embodiment, it issubmitted that it is within the knowledge of one skilled in the art toaffect such feature, structure, or characteristic in connection withother embodiments whether or not explicitly described. After reading thedescription, it will be apparent to one skilled in the relevant art(s)how to implement the disclosure in alternative embodiments.

1. A panel comprising: a polymeric insulated core comprising a steelexoskeleton of steel studs; and a lateral transfer plate comprises anopening to receive a first stud, wherein the opening corresponds to theshape of the first stud, an attachment tab formed by creating theopening.
 2. The panel of claim 1, further comprising fireblockingproximate to the lateral transfer plate.
 3. The panel of claim 1,further comprising a slip transfer plate comprising an opening toreceive the first stud, wherein the opening mirrors the shape of thestud and wherein the slip transfer plate comprises a flange having aslot to receive a fastener for coupling the first stud.
 4. The panel ofclaim 1 wherein the polymeric insulated core further comprises acontiguous precision cut groove cut out of the core configured toreceive a first steel stud, wherein the precision cut groove correspondsto the shape of the first stud.
 5. The panel of claim 1, wherein thefirst stud is a conventionally shaped C steel stud.
 6. The panel ofclaim 5, wherein conventional steel stud comprises a web, a flange and alip.
 7. The panel of claim 1, wherein each of the panels includes atleast one precision cut chase useable to receive utility runs, whereinthe chase further comprises individual channels cut to friction fit atleast one of a wire, cable or tube.
 8. The panel of claim 1, wherein thelateral transfer plate comprises a flange configured to be fastened tothe first stud.
 9. The panel of claim 1, wherein the panel isconstructed from parts in accordance with AISI S200 requirements. 10.The panel of claim 1, wherein the lateral transfer plate is configuredto be integrated into a furring wall panel in which a plurality of studsare arranged in a row.
 11. The panel of claim 1, wherein the lateraltransfer plate is configured to disperse a load between the interior andexterior studs and reduce the unbraced length.
 12. The panel of claim 1,further comprising a slip transfer plate comprising an opening toreceive the first stud, wherein the opening mirrors the shape of thestud and wherein the slip transfer plate comprises a flange having aslot to receive a fastener for coupling the first stud.
 13. The panel ofclaim 1, further comprising an interlocking outside corner steelstructural element and an inside corner steel structural element. 14.The panel of claim 1, wherein the tab is fastened to the stud with atleast one of a screw, rivet, weld, and with adhesive tape.